Trip Checking

THERMAX LTD.
PLANT TRIP INTERLOCK CHECKING REPORT

BOP
O&M SITE:
Set actual RESULT REMARKS/ ANY RE- frequency of

DESCRIPTION UOM METHOD OF TESTING
value value EXPECTED SETTING checking
1 CT FAN
Operate the fan and reduce
level from Level switch Once the testing is
Lube oil level low mm .Ensure that level swich is Fan trips staisfied, normalize the half yearly
isolated from gear box oil level switch
sump
Hammer near the switch
Vibration high mm/s 11 mm/s Fan trips
with a wooden piece as above
2 COAL HANDLING PLANT
Note: the belt sway

Operate the belts as per protection for the longest
sequence and operate belt can be checked by
Belt sway belt trips Every week
manually the belt sway operating the belt. Other
switch sway can be checked by
seq operation
Put one cover in front of

Zero speed Belt trips as above
Zero speed switch
Run the belt, operate local
local stop belt trips as above
stop PB
Rope switch
Run the belt, operate Rope belt trips as above
operation
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THERMAX LTD.
BOP
Sequnce of Belt
Try to operte in reverse Belt does not operation- from farthest
Sequence check as above
sequence take start one to nearest of grzzly
hopper.
3 COMPRESSOR
Remove power fuse and

make compressor ready for
start by opening CW line
etc. and give on command.
See that compressor is not Annually
coming but on command is
there in DCS/ PLC or local
panel. Now do following
tsting one by one
Normalize the switch

Discharge Reduce the set point below
deg C 140 trip indication once protection is Anually
temperture high availabe discharge temp
satisfacorily checked
Gradually close CW out let Normalize the CW valve

CW flow low M3/hr valve for checking the low as above once protection is Anually
flow satisfacorily checked
gradually close inlet CW
CW pressure low Kg/cm2 as above as above Anually
valve
Increase pressure into the
Discharge
Kg/cm2 SW by injecting high as above Annually
pressure high
pressure
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THERMAX LTD.
BOP
Normalize the CW valve

drain out the switch after
LO pressure low SW as above once protection is Annually
due isolating it
Normalize the switch

High element Reduce the set point below
deg C as above once protection is Annually
temp availabe discharge temp
drain out the switch after

Low LO level SW as above as above Annually
due isolating it
4 FIRE WATER PUMP
Keep the pump running and

increase pressure beyound
> 7 kg/cm2 and put on
Jockey Pump
auto. Now reduce pressure
( JP) starts at low Kg/cm2 7 Start quarterly
of the system by opening
pressure
any hydrant. See that at 7.0
kg/cm2 pr. Pump starts
automatically.
As above, once pressure

JP stops at high
Kg/cm2 8 increases >8.0 kg/cm2, it pump stops quarterly
pressure
shoud stop
Reduce the pressure of
JP Stops when AC hydrant below 7 kg/cm2
driven fire pump and sart JP manually. JP stops quarterly
starts Subsequently start AC
pump
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THERMAX LTD.
BOP
Put AC driven pump on
auto by ensuring that
AC driven pump hydrant pressure is above 7
AC pump
starts at low Kg/cm2 6.5 kg/cm2.Take JP on manual quarterly
starts
pressure mode.Reduce the pressure
of hydrant below 6.5
kg/cm2
Put AC driven pump & JP

on Manual ensuring that
Diesel pump hydrant pressure is above 7
Diesel pump
starts at very low Kg/cm2 4.5 kg/cm2. Put Diesel pump quarterly
starts
pressure on auto.Reduce the
pressure of hydrant below
4.5 kg/cm2
4 DM TRANSFER
run one pump and put other

Discharge stand by
on auto. Gradually
pressure low, Kg/cm2 pump put on Annually
decrease header pressure
stand by start auto, starts
by closing discharge valve
Run one pump and

Gradually decrease level
through level trans mitter/ Running
Tank level low % 20 Annually
LSW, ensuring that pump stops
transmitter/ SW are isolated
from tank.
Checked by Witnessed by
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THERMAX LTD.
BOP
Date date
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Interlock in
Tested date Due date service
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THERMAX LTD.
BOILER-1
SITE:
REMARKS/
Set actual RESULT frequency
SNO DESCRIPTION UOM METHOD OF TESTING ANY RE-
value value EXPECTED of checking
SETTING
Put STG on turning gear ,by
HAND TRIP TEST BY Turbine trip & Every
1 Trip pass vacuum protection, reset
MANUALTRIP ESV close opportunity
STG
REMOTE TRIP TEST BY PB
2 Trip as above as above as above
ON GOVERNER PANEL
Operate the turbine at

working speed and do the OS
testing through woodward. It every 3
is advised to test the electrical month
3 OVER SPEED TRIP ( ELET) RPM 109% TURBINE TRIP
OS at operating speed by /available
resetting OS electrical at opportunity.
operating speed. After testing
normalize the set value
Operate the turbine at

working speed and do the OS
testing through woodward. It Atlease once
4 OVER SPEED TRIP ( MECH) RPM 110% TURBINE TRIP
is advised to set electrical OS in year year.
beyond mechanical OS value
as back up protection.
1ST EXTRACTION STEAM

5 kg/cm2 TURBINE TRIP yearly
PRESS HIGH
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THERMAX LTD.
BOILER-1
SITE:
Put STG on turning gear
,normalize pass vacuum
protection, try to reset STG.
STG will not get
Otherwise, pull some vacuum
EXHAUST STEAM PRESS reset. In the
6 kg/cm2 -0.6 above trip value and reset the yearly
HIGH second case
STG. Now reduce vacuum by
turbine must trip
controlling ejector steam
pressuure to trip value. Note
the trip value

7 INLET STEAM TEMP HIGH deg C 540 pass vacuum protection, reset TURBINE TRIP yearly
STG, simulate through DCS
8 INLET STEAM TEMP LOW deg C 465 as above TURBINE TRIP yearly
TURBINE EXHAUST STEAM
9 deg C 120 as above TURBINE TRIP yearly
TEMP HIGH
TURBINE THRUST BRG IN-
ACTIVE TEMP HIGH
TURBINE THRUST BRG
ACTIVE TEMP HIGH
TURBINE FRONT BRG.TEMP
HIGH
TURBINE REAR BRG.TEMP
HIGH
REDUCTION GEAR PINION
FRONT BRG TEMP HIGH
REAR BRG TEMP HIGH
REDUCTION GEAR WHEEL
FRONT BRG TEMP HIGH
REAR BRG TEMP HIGH
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THERMAX LTD.
BOILER-1
SITE:
TURBINE REAR BRG OIL
RETURN TEMP HIGH
TURBINE FRONT BRG OIL
RETURN TEMP HIGH
REDUCTION GEAR BRG OIL
RETURN TEMP HIGH
TURBINE AXIAL
21 mm ± 0.8 as above TURBINE TRIP yearly
DISPLACEMENT HIGH
TURBINE CASING / ROTOR +1.25,
22 mm as above TURBINE TRIP yearly
DIFF.EXPANSION HIGH -1.0
TURBINE FRONT SHAFT
23 micron 85 as above TURBINE TRIP yearly
VIBRATION HIGH
TURBINE REAR SHAFT
VIBRATION HIGH
SHAFT VIBRATION HIGH
SHAFT VIBRATION HIGH
GENERATOR FRONT SHAFT
VIBRATION HIGH
GENERATOR REAR SHAFT
VIBRATION HIGH
29 HOTWELL LEVEL HIGH-HIGH mm as above TURBINE TRIP yearly
30 GOVERNER HEAVY FALT TURBINE TRIP yearly
Reduce control oil pressure every 3
CONTROL OIL PRESSURE by switching off the pump or month
31 kg/cm2 TURBINE TRIP
LOW LOW by draining the transmitter/ /available
switch opportunity.
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THERMAX LTD.
BOILER-1
SITE:
every 3
Reduce LO pressure by by
LUB OIL HEADER PRESSURE month
32 kg/cm2 draining the transmitter/ TURBINE TRIP
LOW LOW /available
switch
opportunity.
33 TG GOVERNER HEAVY FALT TURBINE TRIP

yearly

GENERATOR REAR BRG
34 deg C 105 pass vacuum protection, reset TURBINE TRIP
TEMP HIGH
STG, simulate through DCS
yearly
GENERATOR FRONT BRG
35 deg C 105 as above TURBINE TRIP
TEMP HIGH yearly
GENERATOR FRONT BRG
RET OIL TEMP HIGH yearly
GENERATOR REAR BRG RET
OIL TEMP HIGH yearly
38 MOT TANK LEVEL LOW LOW mm drain Switch TURBINE TRIP
yearly
every 3
Stop Turning gear and AOP
month
39 LO pressure low, AOP start kg/cm2 1 and put AOP on manual. AOP starts
/available
Now put AOP on auto
opportunity.
Checked by Witnessed by
Date date
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Interloc
k in
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THERMAX LTD.
BOILER-1
SITE:
frequency
sl no Equipment interlock/ Permissive UOM set value Method of checking Actual value Remarks of
checking
Make the BFP ready for start

with all the stated permiisives
are healthy.Rack out the
breaker and give start
command. See that actually
pump does not start but start
1 BFP NO- Permissive Annually
indication is there. The above
condition is common for
checking all the
permissives.Now check all the
permissive one by one by
following below processes.
Reduce suction pressure low Stop indication should

by draining the low suction come, once the checking is
Suction pressure Ok kg/cm2
pressure Switch/ transmitter to satisfied, normalize the
trip set value. switch
Discharge valve
Open the discharge valve As above
close
deareator level low mm Drain level transmitter As above
Close suction valve partly so
Suction valve open As above
that lt. sw . Gets disengaged
bearing temp Ok deg C Simulate through DCS As above
Motor winding temp-
deg C as above as above
OK
Motor bearing temp
deg C as above As above
ok
Suction DP Ok kg/cm2 Drain DP switch As above
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THERMAX LTD.
BOILER-1
SITE:
Now put other pump on auto
mode keeping the first pump
on condition. Ensure breaker
interlock
of stand by is racked out.
Check the following interlock
one by one.
Pump put on auto should

start showing start
drain transmitter/ switch to set
Dicharge pr low kg/cm2 indication.Once interlock
value
check is satisfied normalize
the switch/ transmitter.
Running pump Off Switch off running pump as above
Make the CEP ready for start

with all the stated permiisives
are healthy.Remove power
fuse and give start command.
See that actually pump does
2 CEP Permissive not start but start indication is Annually
there. The above condition is
common for checking all the
Stop indication should

Discharge valve come, once the checking is
Open the discharge valve
close satisfied, normalize the
switch
Hotwell level level
mm Drain level transmitter As above
low
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THERMAX LTD.
BOILER-1
SITE:
Close suction valve partly so
Suction valve open As above
that lt. sw . Gets disengaged
Suction DP Ok kg/cm2 Drain DP switch As above
on condition. Ensure power
interlock
fuse of stand by is taken out.
Check the following interlock
one by one.

start showing start
value
Make the MCWP ready for

start with all the stated
permiisives are
healthy.Remove power fuse/
rack out breaker and give start
command. See that actually
3 MCWP Permissive pump does not start but start Annually
indication is there. The above
condition is common for
checking all the
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THERMAX LTD.
BOILER-1
SITE:
lt. SW Open the discharge valve
switch
Cold well level low mm Drain level transmitter As above
interlock Annually
fuse/ breaker of stand by is
out. Check the following
interlock one by one.

start showing start
value
Make the ACWP ready for

start with all the stated
permiisives are
healthy.Remove power fuse
and give start command. See
that actually pump does not
4 ACWP Permissive Annually
start but start indication is
there. The above condition is
common for checking all the
Page 22 of 33
THERMAX LTD.
BOILER-1
SITE:
lt. SW Open the discharge valve
switch
Cold well level low mm Drain level transmitter As above
interlock Annually
fuse/ breaker of stand by is
out. Check the following
interlock one by one.

start showing start
Dicharge pr low kg/cm2 indication.Once interlock Annually
value
Running pump Off Switch off running pump as above Annually

Annually
Annually
Checked
Witnessed by Annually
by
Date date Annually
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Interlock in
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PROTECTION AGAINST GENERATOR FAULT
Current Related Fault Relay name setting
Instantanous phase Over current 50
Residual Directional over current 67N
Stator earth fault
Rotor earth fault
Generator Phase Differential current 87
Zero seq ( ground Zero) Generator Phase
Differential current 87 GD
Negative seq over Current 46
Instantanous neutral Over current 50N
Inverse time Neutral Over current 51N
Three phase inverse time over current with voltage
restrained 51V
Voltage related Fault
Phase Over voltage 59
Neutral Over voltage 59N
Phase under voltage 27
Third harmonic under voltage 27TN
Third harmonic voltage differential 59D
Power related Fault

Low forward power or Over power 32
Reverse power
Excitation Related fault

Over excitation ( V/Hz) 24
Under excitation
Loss of field 40
Inadvertent energization 50/27
Other Fault
Under frequency 81
Over frequency 81
Generator breaker failure 50 BF
Rate of change of freq 81R
THERMAX LTD.
BOILER-1
SITE:
EXPECTED ACTUAL
SNO TAG NO DESCRIPTION METHOD OF TESTING REMARKS
RESULT STATUS
Rack out FD fan breaker & power
fuse for ID , PA & coal feeder/
DCF.Normalize drum level and start
ID, FD , PA & DCF/ CF as per
sequence. Check the following
interlock/ protection as per the below
process.
BOILER TRIP.
Once the checking
Reduce drum level through level Trip Indication
STEAM DRUM LEVEL is satisfactory,
1 transmitter(s) . Ensure that of ID, FD, PA &
LOW LOW normalize the level
transmitter(s) are isolated from drum CF should be in
transmitter (s)
DCS
STEAM DRUM LEVEL

2 Increase drum level by actual filling As above
HIGH HIGH
Increase the FCE pressure by Once the checking

FURNACE PRESSURE injecting air in the transmitter.One air is satisfactory,
3 As above
HIGH HIGH filter regulator/ LP calibrator can be normalize the level
used for the purpose. transmitter (s)
Decrease FCE pressure creating

FURNACE PRESSURE vacuum in the transmitter. LP
4 As above
LOW LOW calibrator can be used for the
purpose.
Page 30 of 33
THERMAX LTD.
BOILER-1
PA FAN , Coal
feeder TRIP
5 FD FAN TRIP Stop command for FD fan from DCS
indication in
DCS
6 PA FAN TRIP Stop command for PA fan ALL DCF TRIP
7 BED TEMP HIGH HIGH Simulate through DCS DCF TRIP

BOILER TRIP.
Trip indication
8 BOTH ID FAN TRIP Stop command for ID fan for FD, PA &
Coal feeder in
DCS
Checked
Witnessed by
by
Date date
Page 31 of 33
Frequency of Interlock in
checking Tested date Due date service
half yearly/ on
opportunity
as above
as above
as above
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as above
as above
as above
as above
Page 33 of 33

Trip Checking

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Trip Checking

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THERMAX LTD.

PLANT TRIP INTERLOCK CHECKING REPORT

Set actual RESULT REMARKS/ ANY RE- frequency of

2 COAL HANDLING PLANT

Note: the belt sway

Put one cover in front of

Remove power fuse and

Normalize the switch

Gradually close CW out let Normalize the CW valve

Normalize the CW valve

Normalize the switch

drain out the switch after

Keep the pump running and

As above, once pressure

Put AC driven pump & JP

run one pump and put other

Run one pump and

Operate the turbine at

Operate the turbine at

1ST EXTRACTION STEAM

Put STG on turning gear ,by

33 TG GOVERNER HEAVY FALT TURBINE TRIP

Put STG on turning gear ,by

Make the BFP ready for start

Reduce suction pressure low Stop indication should

Pump put on auto should

Running pump Off Switch off running pump as above

Make the CEP ready for start

Stop indication should

Pump put on auto should

Running pump Off Switch off running pump as above

Make the MCWP ready for

Pump put on auto should

Running pump Off Switch off running pump as above

Make the ACWP ready for

Pump put on auto should

Running pump Off Switch off running pump as above Annually

Power related Fault

Excitation Related fault

STEAM DRUM LEVEL

Increase the FCE pressure by Once the checking

Decrease FCE pressure creating

6 PA FAN TRIP Stop command for PA fan ALL DCF TRIP

7 BED TEMP HIGH HIGH Simulate through DCS DCF TRIP

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